EP0302447A1 - Polycarbonate et son procédé de fabrication - Google Patents

Polycarbonate et son procédé de fabrication Download PDF

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Publication number
EP0302447A1
EP0302447A1 EP88112543A EP88112543A EP0302447A1 EP 0302447 A1 EP0302447 A1 EP 0302447A1 EP 88112543 A EP88112543 A EP 88112543A EP 88112543 A EP88112543 A EP 88112543A EP 0302447 A1 EP0302447 A1 EP 0302447A1
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EP
European Patent Office
Prior art keywords
general formula
polycarbonate
group
molar fraction
solution
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP88112543A
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German (de)
English (en)
Inventor
Takashi Idemitsu Petrochemical Co. Ltd. Komatsu
Eiichi Idemitsu Petrochemical Co. Ltd. Terada
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Idemitsu Petrochemical Co Ltd
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Idemitsu Petrochemical Co Ltd
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Application filed by Idemitsu Petrochemical Co Ltd filed Critical Idemitsu Petrochemical Co Ltd
Publication of EP0302447A1 publication Critical patent/EP0302447A1/fr
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
    • C08G64/04—Aromatic polycarbonates
    • C08G64/06—Aromatic polycarbonates not containing aliphatic unsaturation
    • C08G64/14—Aromatic polycarbonates not containing aliphatic unsaturation containing a chain-terminating or -crosslinking agent
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
    • C08G64/04—Aromatic polycarbonates
    • C08G64/06—Aromatic polycarbonates not containing aliphatic unsaturation
    • C08G64/08—Aromatic polycarbonates not containing aliphatic unsaturation containing atoms other than carbon, hydrogen or oxygen
    • C08G64/10—Aromatic polycarbonates not containing aliphatic unsaturation containing atoms other than carbon, hydrogen or oxygen containing halogens

Definitions

  • the present invention relates to polycarbonate and a process for production thereof, and more particularly to novel polycarbonate which is excellent in all of flame retardance, impact resistance, fluidity and transparency and also to a process for efficiently producing said novel polycarbonate.
  • a copolymer of tetrahalogenobisphenolsulfone and bisphenol A Japanese Patent Application Laid-Open No. 123294/1976
  • polycarbonate having an aromatic monosulfonyl group at the terminal thereof Japanese Patent Application Laid-Open No. 21497/1979
  • a copolymer of tetrabromobisphenol A and BPA Japanese Patent Application Laid-Open No. 155233/1982
  • polycarbonate having a sulfonic acid salt at the terminal thereof PCT Japanese Patent Application Laid-Open No. 501212/1985
  • Japanese Patent Publication No. 40715/1971 discloses polycarbonate produced using pentabromophenol as a molecular weight modifier.
  • polycarbonates having a bromine content of 4.2% by weight or 3.3% by weight there are prepared only polycarbonates having a bromine content of 4.2% by weight or 3.3% by weight.
  • Polycarbonate having such bromine contents cannot be expected flame retardance of the extent that satisfies the standard V-0 specified in UL 94 1/16 inch (thickness).
  • there is no description concerning impact resistance and fluidity of polycarbonate and, therefore, it can be seen that properties such as impact resistance and fluidity are not taken into consideration at all.
  • Japanese Patent Publication No. 41422/1972 discloses polycarbonate derived from tetrabromobisphenol A which is terminated in halogenated phenols. In this polycarbonate, however, neither impact resistance nor fluidity is taken into consideration and, therefore, it is considered that the polycarbonate is intended to be used merely as a flame retardant.
  • An object of the present invention is to provide polycarbonate which is excellent in all of flame retardance, impact resistance, fluidity and transparency.
  • Another object of the present invention is to provide a process for efficiently producing the above polycarbonate.
  • the present invention relates to a polycarbonate having: a main chain comprising a repeating unit represented by the general formula (A): (wherein R1 to R4 are each a hydrogen atom or an alkyl group having 1 to 4 carbon atoms, and m and n are each an integer of 1 to 4): a pentahalogenophenoxy group represented by the general formula (B): (wherein X1 to X5 are each a halogen atom) at the terminal thereof, the ratio of the molar fraction of the pentahalogenophenoxy group (b) to the molar fraction of the repeating unit (a) plus the molar fraction of the pentahalogenopheoxy group (b) (i.e., b/(a + b)) being 0.03 : 1 to 0.05 : 1; and a viscosity average molecular weight of at least 15,000.
  • the present invention further relates to a process for producing the above polycarbonate which comprises polymerizing an organic dihydroxy compound represented by the general formula (A′): (wherein R1 to R4, m and n are the same as defined above) and a carbonate-forming derivative in a liquid medium in the presence as a molecular weight modifier of pentahalogenophenol represented by the general formula (B′): (wherein X1 to X5 are the same as defined above.
  • A′ organic dihydroxy compound represented by the general formula (A′): (wherein R1 to R4, m and n are the same as defined above) and a carbonate-forming derivative in a liquid medium in the presence as a molecular weight modifier of pentahalogenophenol represented by the general formula (B′): (wherein X1 to X5 are the same as defined above.
  • the polycarbonate of the present invention has a main chain comprising the repeating unit represented by the general formula (A).
  • R1 to R4 may be the same or different and are each a hydrogen atom or an alkyl group having 1 to 4 carbon atoms (e.g., methyl, ethyl, n-propyl, iso-propyl, n-butyl iso-butyl, sec-butyl, and tert-butyl), and m and n are each an integer of 1 to 4.
  • the polycarbonate of the present invention has the pentahalogenophenoxy group represented by the general formula (B) at the terminal thereof.
  • X1 to X5 may be the same or different and are each a halogen atom (e.g., chlorine, bromine and fluorine).
  • Representative examples of the pentahalogenopheoxy group are a pentabromophenoxy group, a pentachlorophenoxy group, a pentafluorophenoxy group and the like.
  • the viscosity average molecular weight of the polycarbonate of the present invention is at least 15,000 and preferably 15,000 to 30,000. If the viscosity average molecular weight is less than 15,000, impact resistance is poor.
  • the ratio of the molar fraction of the pentahalogenophenoxy group (b) to the molar fraction of the repeating unit (a) plus the molar fraction of the pentahalogenophenoxy group (b) is 0.03 : 1 to 0.05 : 1. If the above ratio is less than 0.03 : 1, flame retardance and fluidity are not sufficiently high. On the other hand, if it is in excess of 0.05 : 1, impact resistance is not sufficiently high.
  • the main chain may contain a small amount of a repeating unit or repeating units other than the repeating unit of the general formula (A).
  • polycarbonate of the present invention can be produced by various, it can be produced efficiently and with high quality particularly by the process of the present invention as described above.
  • an organic dihydroxy compound represented by the general formula (A′) and a carbonate-forming derivative are used as starting materials.
  • the organic dihydroxy compound of the general formula (A′) includes various bisphenols.
  • Representative examples of the bisphenols include 2,2-bis(4-hydroxyphenyl) propane (commonly called bisphenol A (BPA)), bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane, 1,1-bis(4-hydroxyphenyl)propane, 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)pentane, 2,2-bis(4-hydroxyphenyl)isopentane, 2,2-bis(4-hydroxyphenyl)hexane, 2,2-bis(4-hydroxyphenyl)isohexane, 4,4-dihydroxytriphenylmethane, 4,4-dihydroxytetraphenylmethane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 2,2-bis(4,4-hydroxy-3-methylphenyl)propane, and 2,2-bis(
  • phosgene As the carbonate-formig derivative, phosgene is usually used. In addition, bromophosgene, diphenyl carbonate, di-p-toly carbonate, phehyl-p-tolyl carbonate, di-p-chlorophenyl carbonate, dinaphthyl carbonate and the like can be used.
  • pentahalogenophenol examples include pentabromophenol, pentachlorophenol, and pentafluorophenol.
  • the repeating unit of the general formula (A) is derived from the organic dihydroxy compound of the general formula (A′) and the carbinate-forming derivative, and the pentahalogenophenoxy group of the general formula (B) as bonded at the terminal is derived from the pentahalonenophenol of the general formula (B′).
  • the amount of the pentahalogenophenol of the general formula (B′) used is determined so that the ratio of b/(a + b) is 0.03 : 1 to 0.05 : 1.
  • the pentahalogenophenol is sufficient to be used in such an amount that the molar ratio of the pentahalogenophenol to the total of the organic dihydroxy compound of the general formula (A′) and the pentahalogenophenol is about 0.03 : 1 to 0.05 : 1.
  • the reaction is carried out in a liquid medium to produce polycarbonate. More specifically, the reaction is carried out according to, for example, the interfacial polymerization method or the pyridine method.
  • the organic dihydroxy compound of the general formula (A′) as dissolved in an aqueous alkali solution e.g., an aqueous sodium hydroxide solution, an aqueous potassium hydroxide solution, and an aqueous sodium carbonate solution
  • an inert organic solvent e.g., methylene chloride, chloroform, chlorobenzene, and carbon tetrachloride
  • the carbonate-forming derivative e.g., phosgene
  • pentahalogenophenol as a molecular weight modifier is added to the reaction system, previously or at a stage that the reaction proceeds to a certain extent.
  • tertiary amine e.g., triethylamine
  • a catalyst i.e., a dehydrohalogenation agent
  • the reaction system is preferably cooled with water or ice because the reaction is exothermic.
  • the pH be maintained at 10 or more by adding an alkali while measuring with a pH meter.
  • the organic dihydroxy compound of the general formula (A′) as a starting material and pentahalogenophenol as a molecular weight modifier are dissolved in pyridine or a mixed solvent of pyridine and an inert solvent, and on blowing the carbonate-forming derivative (e.g., phosgene) in the solution as prepared above, the desired polycarbonate results.
  • the amounts of pentahalogenophenol and the carbonate-forming derivative (e.g., phosgene) being introduced determine the degree of polymerization, that is, molecular weight of the resulting polycarbonate.
  • the amounts of pentahalogenophenol and the carbonate-forming derivative being introduced are determined depending on the purpose of use of the polycarbonate.
  • the amount of the carbonate-­ forming derivative introduced per hour is appropriately controlled so that the total amount of the carbonate-forming derivative introduced until the reaction is completed is equal to the necessary amount of the carbonate-forming derivative to be supplied.
  • the desired polycarbonate is precipitated.
  • a precipitating agent e.g., methanol
  • the present invention is preferably carried out by the following three embodiments: method (1) in which a solution of the organic diyhdroxy compound of the general formula (A′) in an aqueous alkali solution, a solution of pentahalogenophenol in an aqueous alkali solution, an organic solvent (e.g., methylene chloride) and tertiary amine (e.g., triethylamine) as a catalyst are mixed, and the carbonate-forming derivative (e.g., phosgene) is blown in the above mixture to cause polycondensation, thereby producing the desired polycarbonate; method (2) in which a polycarbonate oligomer formed from the organic dihydroxy compound of the general formula (A′) and the carbonate-forming derivative is mixed with a tertiary amine catalyst and solution of pentahalogenophenol in an aqueous alkali solution is added thereto to cause preliminary polymerization and, thereafter, a solution of the organic dihydroxy compound of the general formula
  • the polycarbonate of the present invention is excellent in flame retardance and has good fluidity, and further has sufficiently high impact resistance and is excellent in transparency.
  • the flame retardance as determined according to UL-94 1/16 inch (thickness) (Underwriter's Laboratories Subject 94, using a test piece 1/16 inch in thickness) is V-0
  • the Izod impact value (notched, ductile fracture at ordinary temperature) as a measure of impact resistance is at least 50 kg ⁇ cm/cm
  • the flow value as a measure of fluidity, indicating a capability for molding a thin film is at least 4 X 10 ⁇ 2 ml/sec
  • the transparency is high.
  • the polycarbonate of the present invention can be widely used in production of various industrial products such as home electric appliances, office automation apparatuses, construction materials and so on.
  • Polycarbonate having the above characteristics can be efficiently produced by the process of the present invention.
  • reaction mixture was separated into an aqueous layer and a methylene chloride layer containing the formed polymer.
  • This methylene chloride layer was washed with water, an acid (0.1 N hydrochloric acid) and water in this sequence. Upon removal of the methylene chloride from the methylene chloride layer at 40°C under reduced pressure, a white powder was obtained. This white powder was dried at 120°C for one day and night and, thereafter, melted and pelletized by the use of an extruder. The viscosity average molecular weight of the pellet polymer was 17,600. The molar fraction of the pentabromophenxy group in the polymer was 4.7 mol%.
  • the pellets were injection molded at a temperature of 280°C under an injection pressure of 56 kg/cm2 by the use of an injection molding machine to obtain a test piece. This test piece was measured for Izod impact resistance and flame retardance, and its transparency was determined with the eye. The flow value of the pellet was measured by the use of a flow tester.
  • the bromine content of the pellet as measured by the Volhard method after alkali decomposition was 7.1% by weight.
  • IR infrared absorption
  • NMR nuclear magnetic resonance
  • An aqueous bisphenol A solution (prepared by dissolving 60 kg of bisphenol A in 400 L of a 5% aqueous sodium hydroxide solution), an aqueous pentabromophenol solution (prepared by dissolving 82 kg of pentabromophenol in 400 L of a 4% aqueous sodium hydroxide solution), methylene chloride, and an aqueous triethylamine solution (concentration: 33 g/L) were introduced in a tubular reactor (inner diameter: 10 mm; lenth: 10 m) at flow rates of 138 L/hr, 11 L/hr, 50 L/hr and 100 ml/hr, respectively, and phosgene was blown in the tubular reactor in parallel at a flow rate of 11 kg/hr to react.
  • the tubular reactor was a jacketed tube, and the discharge temperature of the reaction mixture was maintained at 25°C by passing cooling water through the jacketed portion.
  • the reaction mixture was introduced in a 100-liter vessel-type reactor and the reaction was continued for 3 hours. Then the reaction mixture was treated in the same manner as in Example 1, and the white powder thus obtained was analyzed in the same manner as in Example 1.
  • aqueous bisphenol A solution, an aqueous pentabromophenol solution, an aqueous triethylamine solution all the same as used in Example 4, and methylene chloride were introduced in the same tubular reactor as used in Example 4 at flow rates of 138 L/hr, 11 L/hr, 100 ml/hr and 50 L/hr, respectively, and phosgene was blown therein in parallel at a flow rate of 11 kg/hr to react. On allowing the reaction mixture to stand at room temperature, a methylene chloride solution of an oligomer was separated as a lower layer.
  • the number average molecular weight of the oligomer was 850, and the concentration of the chloroformate group was 0.7 mol/L.
  • Example 1 Then the reaction mixture was treated in the same manner as in Example 1, and the white powder thus obtained was analyzed in the same manner as in Example 1.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Polyesters Or Polycarbonates (AREA)
EP88112543A 1987-08-07 1988-08-02 Polycarbonate et son procédé de fabrication Withdrawn EP0302447A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP196268/87 1987-08-07
JP62196268A JPS6440523A (en) 1987-08-07 1987-08-07 Polycarbonate and production thereof

Publications (1)

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EP0302447A1 true EP0302447A1 (fr) 1989-02-08

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EP88112543A Withdrawn EP0302447A1 (fr) 1987-08-07 1988-08-02 Polycarbonate et son procédé de fabrication

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US (1) US4888410A (fr)
EP (1) EP0302447A1 (fr)
JP (1) JPS6440523A (fr)
KR (1) KR940005874B1 (fr)
BR (1) BR8803903A (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0650096A2 (fr) * 1993-10-12 1995-04-26 Kureha Kagaku Kogyo Kabushiki Kaisha Feuille de transfert à base d'une résine au polycarbonate
US5612163A (en) * 1993-10-12 1997-03-18 Kureha Kagaku Kogyo Kabushiki Kaisha Transfer sheet of polycarbonate-based resin

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5037937A (en) * 1987-02-13 1991-08-06 Idemitsu Petrochemical Co., Ltd. Novel polycarbonate resins, process for production of said resins, and compositions containing said resins
JP2564565B2 (ja) * 1987-09-16 1996-12-18 三菱化学株式会社 ポリカーボネート樹脂の製造方法
KR19990015913A (ko) * 1997-08-12 1999-03-05 김윤 난연성 폴리카보네이트 수지 조성물
US8143369B2 (en) 2009-06-02 2012-03-27 International Business Machines Corporation Polymers bearing pendant pentafluorophenyl ester groups, and methods of synthesis and functionalization thereof
CN115651183B (zh) * 2022-11-11 2024-02-27 万华化学集团股份有限公司 一种光气法共聚碳酸酯的制备方法、由其制备的共聚碳酸酯及应用

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BE699028A (fr) * 1966-06-02 1967-11-03
US3751400A (en) * 1971-07-29 1973-08-07 Gen Electric High ignition temperature polymers substituted with halogen substituted aromatic groups

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA894877A (en) * 1972-03-07 Mobay Chemical Company Flame resistant polycarbonates
US4831100A (en) * 1987-06-25 1989-05-16 Idemitsu Petrochemical Co., Ltd. Halogenated copoly carbonate end capped with pentahalaphenoxy group

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BE699028A (fr) * 1966-06-02 1967-11-03
US3751400A (en) * 1971-07-29 1973-08-07 Gen Electric High ignition temperature polymers substituted with halogen substituted aromatic groups

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0650096A2 (fr) * 1993-10-12 1995-04-26 Kureha Kagaku Kogyo Kabushiki Kaisha Feuille de transfert à base d'une résine au polycarbonate
EP0650096A3 (fr) * 1993-10-12 1996-01-17 Kureha Chemical Ind Co Ltd Feuille de transfert à base d'une résine au polycarbonate.
US5612163A (en) * 1993-10-12 1997-03-18 Kureha Kagaku Kogyo Kabushiki Kaisha Transfer sheet of polycarbonate-based resin

Also Published As

Publication number Publication date
BR8803903A (pt) 1989-02-28
JPS6440523A (en) 1989-02-10
KR940005874B1 (ko) 1994-06-24
US4888410A (en) 1989-12-19
KR890003830A (ko) 1989-04-18

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